Software alone can’t fix problems – only highlight them. At PPMA Total Show (NEC, Birmingham, 23-25 September, Stand B80), Harford Control will show why integration with dedicated hardware is essential for in-process control, greater efficiency, and real results on the line
Digital transformation is a necessity, not a luxury. Yet, as manufacturers embrace Industry 4.0, many fall into the trap of assuming that software alone will drive meaningful change. Dashboards, reports, and analytics are useful – but they’re not enough. Software can monitor; it can’t control. It highlights problems but can’t fix them. And in manufacturing, where every second and gram counts, that distinction matters.
At Harford Control, we’ve worked closely with manufacturers for over 55 years, supporting continuous improvement through integrated systems. Time and again, we’ve seen businesses invest in software-only solutions expecting rapid ROI, only to find themselves firefighting the same issues months later. Why? Because software without hardware integration leaves a gap between insight and action.
Take, for example, an overfilling issue. A software-only system might flag giveaway above target – but by the time the report is reviewed, hundreds of packs may already have been affected. The problem is spotted, but not solved instantly. The operator is then tasked with manual adjustments, often under pressure and prone to error.
Now consider an integrated system – where software is connected to in-line checkweighers, vision systems, sensors, and PLCs. The moment giveaway begins to drift, the system not only detects it but self-corrects, adjusting the filler automatically. Waste is avoided. Quality is preserved. Efficiency is protected.
This is the Harford approach: seamless integration of software and hardware for real-time, in-process control – not post-production damage control.
Our Manufacturing Information System (MIS) and Manufacturing Execution System (MES) are built around four pillars critical to modern production:
Product Quality
- Paperless quality
- Laboratory Information Management Systems (LIMS)
- Materials and process quality
- Full traceability from raw material to finished good
- Vision inspection and barcode inspection
Legal Compliance
- Legal metrology
- Autocoding to prevent mislabelling and wrong date coding
- Direct machine and ERP/SAP integration
Production Efficiency
- OEE and short interval control
- Centrelining and real-time reporting
- Labour and energy monitoring
Manufacturing Yield
- Weight control and fill optimisation
- Energy and material waste reduction
- Process integration and loss monitoring
Not every factory requires every module. Our solutions are modular and tailored, with the flexibility to deliver maximum value without unnecessary complexity.
Here’s how software-only solutions compare with fully integrated systems:
| Feature | Software-Only | Software + Hardware |
| Data Accuracy | Manual, error-prone | Automated, highly accurate |
| Responsiveness | Delayed | Real-time |
| Process Control | Reactive | Proactive, self-correcting |
| Quality Assurance | Post-production | In-process, continuous |
| Waste Reduction | Limited | High impact |
| Operator Dependence | High | Low |
Harford Control provides fully integrated solutions that combine best-in-class software with robust hardware – reducing operator burden, automating checks, and driving consistency. By closing the loop between detection and correction, our systems enable manufacturers to move from reactive, post-production firefighting to proactive, in-process control – improving performance exactly where it matters: on the factory floor.
This year, we’re pleased to be partnering with Etavoni at the PPMA Show on Stand B80, where we’ll be demonstrating how the seamless integration of software and hardware empowers manufacturers to reduce waste, improve compliance, and unlock real-time, in-process control.
Come and see how our clients are using Harford MIS/MES to drive continuous improvement and maintain a competitive edge in a fast-evolving industry.
Ready to move beyond monitoring and start making meaningful improvements?
Get in touch at info@harfordcontrol.com or call +44 (0)1225 764461 to explore how we can support your digital transformation journey.
